Golf club head having a multi-material face and method of manufacture

ABSTRACT

A golf club with a multi-material face is disclosed herein. More specifically, the golf club head in accordance with the present invention has a multi-material striking face portion that is made out of a backing layer having a frontal pocket, made out of titanium, and an insert, made out of a composite material, adapted to be inserted into the frontal pocket. The frontal pocket and the insert could have complementary dovetail shaped undercut features to create a mechanical bond between these two components.

RELATED APPLICATIONS

This application is a Continuation-In-Part (CIP) of U.S. patentapplication Ser. No. 17/186,514, filed Feb. 2, 2021, which is aContinuation (CON) of U.S. patent application Ser. No. 17/098,277, filedon Nov. 13, 2020, now U.S. Pat. No. 11,186,016, which is a CIP of U.S.patent application Ser. No. 16/453,095, filed on Jun. 26, 2019, now U.S.Pat. No. 10,940,617, which is a CON of U.S. patent application Ser. No.14/581,090, filed on Dec. 23, 2014, now U.S. Pat. No. 10,357,901, whichis a CIP of U.S. patent application Ser. No. 14/070,311, filed Nov. 1,2013, now U.S. Pat. No. 9,192,826, which is a CIP of U.S. patentapplication Ser. No. 13/326,967, filed on Dec. 15, 2011, now U.S. Pat.No. 8,876,629, which is a continuation-in-part of U.S. patentapplication Ser. No. 12/832,461, filed on Jul. 8, 2010, now U.S. Pat.No. 8,221,261, the disclosure of which are all incorporated by referencein their entirety.

FIELD OF THE INVENTION

The present invention relates generally to a golf club head having amulti-material face. More specifically, the present invention relates toa golf club head with a striking face having a pocket at the frontalportion of the striking face. The pocket at the frontal portion of thestriking face may be filled with a material having a different densitythan the material used to form the remainder of the striking face. Themulti-material striking face in accordance with the present inventionmay utilize a lighter second material having a second density to fill inthe pocket created by the striking face, while the remainder of thestriking face utilizes a heavier first material that has a firstdensity. The golf club head created by this multi-material striking facemay have a Characteristic Time (CT) slope of greater than about 5 andless than about 50 measured in accordance with the United States GolfAssociation's (USGA's) Characteristic Time (CT) test.

BACKGROUND OF THE INVENTION

In order to improve the performance of a golf club, golf club designershave constantly struggled with finding different ways to hit a golf balllonger and straighter. Designing a golf club that hits a golf balllonger may generally require an improvement in the ability of the golfclub head to effectively transfer the energy generated by the golferonto a golf ball via the golf club. Hitting a golf ball straighter, onthe other hand, will generally require an improvement in the ability ofthe golf club to keep the golf ball on a relatively straight path evenif the golf ball is struck off-center; as a golf ball that is struck atthe center of the golf club head will generally maintain a relativelystraight flight path.

Effectively transferring the energy generated by the golfer onto a golfball in order to hit a golf ball further may be largely related to theCoefficient of Restitution (COR) between the golf club and the golfball. The COR between a golf club and a golf ball may generally relateto a fractional value representing the ratio of velocities of theobjects before and after they impact each other. U.S. Pat. No. 7,281,994to De Shiell et al. provides one good example that explains this CORconcept by discussing how a golf club head utilizing a thinner strikingface may deflect more when impacting a golf ball to result in a higherCOR; which results in greater travel distance.

Being able to hit a golf ball relatively straight even when the clubstrikes a golf ball at a location that is offset from the center of thestriking face may generally involve the ability of the golf club toresist rotational twisting; a phenomenon that occurs naturally duringoff-center hits. U.S. Pat. No. 5,058,895 to Igarashi goes into moredetail on this concept by discussing the advantages of creating a golfclub with a higher Moment of Inertia (MOI), which is a way to quantifythe ability of a golf club to resist rotational twisting when it strikesa golf ball at a location that is offset from the geometric center ofthe golf club head. More specifically, U.S. Pat. No. 5,058,895 toIgarashi utilizes weights at the rear toe, rear center, and real heelportion of the golf club head as one of the ways to increase the MOI ofthe golf club head, which in turn allows the golf club to hit a golfball straighter. It should be noted that although the additional weightsaround the rear perimeter of the golf club head may increase the MOI ofthe golf club, these weights can not be added freely without concern forthe overall weight of the golf club head. Because it may be undesirableto add to the overall weight of the golf club head, adding weight to therear portion of the golf club head will generally require that sameamount of weight to be eliminated from other areas of the golf clubhead.

Based on the two above examples, it can be seen that removing weightfrom the striking face of the golf club head not only allows the golfclub head to have a thinner face with a higher COR, the weight removedcan be placed at a more optimal location to increase the MOI of the golfclub head. One of the earlier attempts to remove unnecessary weight fromthe striking face of a golf club can be seen in U.S. Pat. No. 5,163,682to Schmidt et al. wherein the striking face of a golf club head has avariable thickness by making the part of the striking face that is notsubjected to the direct impact thinner.

U.S. Pat. No. 5,425,538 to Vincent et al. shows an alternative way toremove unnecessary weight from the striking face of a golf club byutilizing a fiber-based composite material. Because fiber-basedcomposite materials may generally have a density that is less than thedensity of traditional metals such as steel or titanium, the simplesubstitute of this fiber-based composite material alone will generate asignificant amount of discretionary weight that can be used to improvethe MOI of a golf club. Fiber-based composite materials, because oftheir relatively lightweight characteristics, tend to be desirableremoving weight from various portions of the golf club head. However,because the durability of such a lightweight fiber-based compositematerial can be inferior compared to a metallic type material,completely replacing the striking face of a golf club with thelightweight fiber-based composite material could sacrifice thedurability of the golf club head.

U.S. Pat. No. 7,628,712 to Chao et al. discloses one way to improve thedurability of striking face made out of a fiber-based composite materialby using a metallic cap to encompass the fiber-based composite materialused to construct the striking plate of the golf club head. The metalliccap aids in resisting wear of the striking face that results fromrepeated impacts with a golf ball, while the rim around the side edgesof the metallic ring further protects the composite from peeling anddelaminating. The utilization of a metallic cap, although helps improvethe durability of the striking face of the golf club head, may not be aviable solution, as severe impact could dislodge the fiber-basedcomposite from the cap.

In addition to the durability concerns of the fiber resin matrix itself,utilizing composite materials to form the striking face of a golf cluboffers additional challenges. More specifically, one of the major designhurdles arises when a designer attempts to bond a fiber-based compositematerial to a metallic material, especially at a location that issubjected to high stress levels normally generated when a golf club hitsa golf ball. Finally, the usage of composite type materials to form thestriking face portion of the golf club head may also be undesirablebecause it alters the sound and feel of a golf club away from what agolfer are accustomed to, deterring a golfer from such a product.

Ultimately, despite all of the attempt to improve the performance of agolf club head by experimenting with alternative face materials, theprior art lacks a way to create a striking face that saves weight,improves COR, and is sufficiently durable without sacrificing the soundand feel of the golf club head. Hence, as it can be seen from above,there is a need in the field for a golf club head having a fiber basedcomposite striking face that can save weight, improve the COR of thegolf club head, and can endure the high stress levels created by theimpact with a golf ball, all without sacrificing the sound and feel ofthe golf club head.

BRIEF SUMMARY OF THE INVENTION

One aspect of the present invention is a golf club head comprising astriking face and a body portion. The striking face is located near aforward portion of the golf club head while the body portion isconnected to an aft portion of the striking face. The striking facefurther comprising a perimeter portion made out of a first materialhaving a first density around a border of the striking face and acentral portion near a center of the striking face surrounded by theperimeter portion; wherein the central portion defines a pocket in thecenter of the striking face. The body portion further comprises a crown,a sole, and a skirt. The pocket formed at the central portion of thestriking face is filled with a face insert that is made out of a secondmaterial having a second density; wherein the second density is lessthan the first density. Finally, the striking face disclosed above has acharacteristic time slope of greater than about 5 and less than about50.

In another aspect of the present invention, a golf club head is providedcomprising a body made out of a first material having a first densityhaving a front portion defining a pocket therein, and a face insert madeout of a second material having a second density disposed within saidpocket; wherein the second density is less than the first density. Thestriking face has a characteristic time slope of greater than about 5and less than about 50, and the golf club head has a first peakfrequency to volume ratio of greater than about 7.0 hertz/, the firstpeak frequency to volume ratio is defined as a first peak frequency of asignal power diagram of the sound of the golf club head as it impacts agolf ball divided by a volume of the golf club head.

In a further aspect of the present invention, a golf club head isprovided comprising a striking face made out of a first material havinga first density located near a forward portion of the golf club head,said striking face defining a pocket at a center of the striking face,and a face insert made out of a second material having a second densitypositioned within the pocket; wherein the second density is less thanthe first density. The striking face disclosed here also comprises anundercut around a perimeter of the pocket.

In a further aspect of the present invention the central portion of thestriking face further defines a pocket having a dovetail shapedundercut, and the pocket is filled with a face insert having a dovetailshaped protrusion around its perimeter, the dovetail shaped protrusionis adapted to engage the dovetail shaped undercut.

In a further aspect of the present invention the golf club head has aPeak Power to Frequency Ratio of between 2.5*10⁻⁵ watts/hertz and lessthan about 5*10⁻⁵ watts/hertz, the Peak Power to Frequency Ratio isdefined as an amplitude of a first peak power of signal power diagramdivided by the frequency where the first peak power occurs.

In a further aspect of the present invention the crown portion of thegolf club head further comprises a constant thickness portion locatednear the striking face and a transition portion location aft of theconstant thickness portion.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdrawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the invention will beapparent from the following description of the invention as illustratedin the accompanying drawings. The accompanying drawings, which areincorporated herein and form a part of the specification, further serveto explain the principles of the invention and to enable a personskilled in the pertinent art to make and use the invention.

FIG. 1 shows a perspective view of a golf club head in accordance withan exemplary embodiment of the present invention;

FIG. 2 shows an exploded perspective view of a golf club head with theface insert detached from its pocket within the golf club head inaccordance with an exemplary embodiment of the present invention;

FIG. 3 shows a frontal view of the golf club head in accordance with anexemplary embodiment of the present invention;

FIG. 4 shows a cross-sectional view of the golf club head taken alongcross-sectional line A-A′ shown in FIG. 3 in accordance with anexemplary embodiment of the present invention;

FIG. 5 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with one exemplary embodiment of the present invention;

FIG. 6 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further exemplary embodiment of the present invention;

FIG. 6A shows a further enlarged cross-sectional view of the golf clubhead focusing on the perimeter of the pocket in accordance with afurther exemplary embodiment of the present invention;

FIG. 6B shows a further enlarged cross-sectional view of the golf clubhead focusing on the perimeter of the pocket in accordance with afurther exemplary embodiment of the present invention;

FIG. 6C shows a further enlarged cross-sectional view of the golf clubhead focusing on the perimeter of the pocket in accordance with afurther exemplary embodiment of the present invention;

FIG. 6D shows a further enlarged cross-sectional view of the golf clubhead focusing on the perimeter of the pocket in accordance with afurther exemplary embodiment of the present invention;

FIG. 7 shows a signal power diagram of a prior art golf club headquantifying the sound of the prior art golf club head;

FIG. 8 shows a signal power diagram of a different prior art golf clubhead quantifying the sound of the different prior art golf club head;

FIG. 9 shows a signal power diagram of an exemplary embodiment of thepresent invention that quantifies the sound of the current exemplarygolf club head;

FIG. 10 shows characteristic time plots of the various data collectedfrom an exemplary inventive golf club head in accordance with the USGACT test;

FIG. 11 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 12 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 13 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 14 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 15 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 16 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 17 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 18 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 19 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 20 shows a stress and strain diagram of the fiber within thecomposite material used to make the face insert in accordance with anexemplary embodiment of the present invention;

FIG. 21 shows an exploded perspective view of a particular type of fiberorientation used to construct the face insert in accordance with anexemplary embodiment of the present invention;

FIG. 22 shows an exploded perspective view of a different type of fiberorientation used to construct the face insert in accordance with adifferent exemplary embodiment of the present invention;

FIG. 23 shows an exploded perspective view of a different type of fiberorientation used to construct the face insert in accordance with adifferent exemplary embodiment of the present invention;

FIG. 24 shows an exploded cross-sectional view of a golf club head inaccordance with a further alternative embodiment of the presentinvention;

FIG. 25 shows an exploded cross-sectional view of a golf club head inaccordance with a further alternative embodiment of the presentinvention;

FIG. 26 shows an exploded cross-sectional view of a golf club head inaccordance with a further alternative embodiment of the presentinvention;

FIG. 27 shows an enlarged cross-sectional view of a the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 28 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 29 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 30 shows an enlarged cross-sectional view of the golf club headfocusing on the striking face portion of the golf club head inaccordance with a further alternative exemplary embodiment of thepresent invention;

FIG. 31 shows a cross-sectional view of a golf club head in accordancewith an alternative embodiment of the present invention;

FIG. 32 shows a cross-sectional view of a golf club head in accordancewith a further alternative embodiment of the present invention;

FIG. 33 shows an enlarged cross-sectional view of the striking faceportion of a golf club head in accordance with the alternativeembodiment of the present invention shown in FIG. 32;

FIG. 34 shows an enlarged cross-sectional view of the striking faceportion of a golf club head in accordance with an even furtheralternative embodiment of the present invention;

FIG. 35 shows a top view of a golf club head in accordance with thealternative embodiment of the present invention shown in FIG. 34;

FIG. 36 shows a flow chart of a method of manufacturing a multi-materialface of a golf club head in accordance with an exemplary embodiment ofthe present invention;

FIG. 37 shows an enlarged cross-sectional view of the striking faceportion of a golf club head during the method of manufacturing;

FIG. 38 shows an enlarged cross-sectional view of the striking faceportion of a golf club head during the method of manufacturing;

FIG. 39 shows an enlarged cross-sectional view of the striking faceportion of a golf club head during the method of manufacturing;

FIG. 40 shows an enlarged cross-sectional view of the striking faceportion of a golf club head in accordance with the alternativeembodiment of the present invention;

FIG. 41 shows an enlarged cross-sectional view of the striking face of agolf club head in accordance with a further alternative embodiment ofthe present invention;

FIG. 42 shows a further enlarged cross-sectional view of the golf clubhead focusing on the perimeter of the pocket in accordance with afurther alternative embodiment of the present invention; and

FIG. 43 shows a further enlarged cross-sectional view of the golf clubhead focusing on the perimeter of the pocket in accordance with afurther alternative embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description describes the best currentlycontemplated modes of carrying out the invention. The description is notto be taken in a limiting sense, but is made merely for the purpose ofillustrating the general principles of the invention, since the scope ofthe invention is best defined by the appended claims.

Various inventive features are described below and each can be usedindependently of one another or in combination with other features.However, any single inventive feature may not address any or all of theproblems discussed above or may only address one of the problemsdiscussed above. Further, one or more of the problems discussed abovemay not be fully addressed by any of the features described below.

FIG. 1 of the accompanying drawings shows a perspective view of a golfclub head 100 in accordance with an exemplary embodiment of the presentinvention. More specifically, FIG. 1 shows a golf club head 100 with astriking face 102 located at a forward portion of the golf club head 100with a body portion connected to an aft portion of the striking face102. The aft body portion of the golf club head 100, in this currentexemplary embodiment, may generally be comprised of a crown 104, a sole106, and a skirt 108. The striking face 102 described in this currentexemplary embodiment of the present invention may generally have aperimeter portion 110 around the external border of the striking face102 and a central portion 112 at the central region of the striking face102. This distinction between the perimeter portion 110 and the centralportion 112 of the striking face 102 is important in this currentexemplary embodiment of the present invention because a differentmaterial could be used to construct the central portion 112 of thestriking face 102 than what is used to for the remainder of the golfclub head 100, including the perimeter portion 110. Despite the above,perimeter portion 110 could also be constructed out of a differentmaterial than the remainder of the golf club head 100 as well as thestriking face 102 to further improve the performance of the golf clubhead 100 without departing from the scope and content of the presentinvention.

In one exemplary embodiment of the present invention the perimeterportion 110 of the striking face 102 may generally be constructed out ofa first material that may generally be metallic with a relatively highfirst density; for example, titanium or steel. These materials, althoughtypically strong enough to withstand the impact forces between a golfclub head 100 and a golf ball, tend to be on the heavy side. Morespecifically, steel, being the heavier of the two materials mentionedabove, may generally have a density of between about 5.0 g/cm³ and 8.00g/cm³. Titanium, on the other hand, may generally be less dense thansteel, with a density of about 4.00 g/cm³ to about 5.00 g/cm³.

With discretionary weight within a golf club at such a premium, anyamount of weight that can be saved from any portion of the golf clubhead 100 can be helpful in improving the Center of Gravity (CG) locationand the Moment Of Inertia (MOI) of the golf club head 100. Hence, in anattempt to save weight from the striking face 102 of the golf club head100, the current exemplary embodiment of the present invention shown inFIG. 1 may utilize a second material with a relatively low seconddensity to construct the central portion 112 of the striking face 102.More specifically, the central portion 112 of the striking face 102 maybe constructed using an aluminum material with a density of about 2.7g/cm³, a magnesium material with a density of about 1.738 g/cm³, acomposite type material with a density of about 1.70 g/cm³, or any othermaterial having a lower density than the density of the first materialall without departing from the present invention. Due to the lightersecond density of the second material used to construct the centralportion 112, the total weight of the entire striking face 102 may besignificantly less and in the range of about 15 to about 25 grams;especially when compared to a striking face 102 that is constructedcompletely out of a denser material such as titanium. This weightsavings may generally be calculated based on a striking face 112 that isabout 60 mm to 80 mm wide, about 25 mm to 50 mm high, and about 2.0 mmto 3.5 mm thick. It is worth noting that utilizing a second materialwith a lower second density to construct the central portion 112 of thestriking face 102 may come with certain design challenges, as materialshaving a lower density may not be sufficiently strong enough towithstand the impact forces between a golf club head 100 and a golfball.

The current invention, in order to address the durability issue above,may utilize a dual layered central portion 112 comprised out of twodifferent materials that could offer up a combination of both thelightweight benefits of the second material in conjunction with thestrength and durability benefits of the first material. FIG. 2 of theaccompanying drawings showing an exploded perspective view of a golfclub head 200 gives a better illustration of the dual layered centralportion 212 in accordance with an exemplary embodiment of the presentinvention. More specifically, the exploded view of golf club head 200allows the face insert 220 and the pocket 222 to be shown. Because thepocket 222 shown in the current exemplary embodiment of the presentinvention is not designed to completely penetrate the entire thicknessof the central portion of the striking face 210, it leaves a layer ofmetallic first material to serve as a backing to the lightweight secondmaterial used for the face insert 220. The face insert 220, as discussedabove being made out of a lightweight second material, may generally beconstructed independently from the remainder of the golf club head 200,and inserted into its resting place within the pocket 222 after the golfclub head is completed. Finally, it is worth noting that the geometry ofthe face insert 220 may generally mimic the geometry of the pocket 222,allowing the two components to be seamlessly assembled with one another.

Face insert 220, although discussed above as being capable of beingcomprised out of numerous types of light density materials, maygenerally be comprised out of composite type material in one exemplaryembodiment of the present invention. Composite type materials, asreferred to in this current invention, may generally apply to engineeredmaterials made from two or more constituent materials with significantlydifferent physical or chemical properties which remain separate anddistinct on a macroscopic level. More specifically, composite typematerial may refer to woven webs of carbon fiber that is impregnatedwith a thermoplastic or thermohardenable resin material; more commonlyknown as resin impregnated carbon fiber.

FIG. 3 of the accompanying drawings shows a frontal view of a golf clubhead 300 in accordance with an exemplary embodiment of the presentinvention. The frontal view of the golf club head 300 shows the relativesize, distance, and percentage of the central portion 312 compared tothe perimeter portion 310 as well as the striking face 302. Morespecifically, in this exemplary embodiment of the present invention, thestriking face 302 may generally have a frontal surface area of greaterthan about 3600 mm² and less than about 4000 mm², more preferablygreater than about 3300 mm² and less than about 3900 mm², and mostpreferably about 3800 mm². The central portion 312, on the other hand,may generally have a frontal surface area of greater than about 2500 mm²and less than about 2900 mm², more preferably greater than about 2600mm² and less than about 2800 mm², and most preferably about 2700 mm².Finally, the frontal surface area of the perimeter portion 310 maygenerally be able derived by subtracting the area of the central portion312 from the striking face 302, yielding a range of greater than about900 mm² and less than about 1300 mm², more preferably greater than about1000 mm² and less than about 1200 mm², and most preferably about 1100mm². It should be noted that the central portion 312 shown in thecurrent exemplary embodiment may mimic the external geometry of thestriking face 302 in order to improve the coverage of the central regionwithout departing from the scope and content of the present invention.

In order to have a sufficiently large pocket at the central portion 312that is comprised out of a lightweight second material, the centralportion 312 must make up a significant portion of the striking face 302.Alternatively speaking, the central portion to striking face ratio needsto be greater than about 0.65, more preferably greater than about 0.70,and most preferably greater than about 0.75. The central portion tostriking face ratio is defined as the frontal surface area of thecentral portion 312 divided by the frontal surface area of the strikingface 302 as shown below in Equation (1):

$\begin{matrix}{{{Central}\mspace{14mu}{Portion}\mspace{14mu}{to}\mspace{14mu}{Striking}\mspace{14mu}{Face}\mspace{14mu}{Ratio}} = \frac{{Frontal}\mspace{14mu}{Surface}\mspace{14mu}{Area}\mspace{14mu}{of}\mspace{14mu}{Central}\mspace{14mu}{Portion}}{{Frontal}\mspace{14mu}{Surface}\mspace{14mu}{Area}\mspace{14mu}{of}\mspace{14mu}{Striking}\mspace{14mu}{Face}}} & {{Eq}.\mspace{14mu}(1)}\end{matrix}$

Ultimately, the striking face 302 could be divided into a centralportion 312 and a perimeter portion 313, wherein the central portion 312defines a pocket that can be filled with the secondary materialmentioned above.

The frontal view of the golf club head 300 shown in FIG. 3 also showsthe offset of the central portion 312 away from the perimeter of thestriking face 302 being at an offset distance d1, defined as thedistance between the perimeter of the striking face 302 and theperimeter of the central portion 312. Offset distance d1, as shown inthis current exemplary embodiment, may generally help define the size ofthe pocket within the central portion 312, which determines the amountof second material that can be used to fill in the pocket to alter theperformance of the golf club head 300. In one exemplary embodiment ofthe present invention, offset distance d1 may generally be less thanabout 0.5 inches, more preferably less than about 0.33 inches, and mostpreferably greater than about 0.25 inches all without departing from thescope and content of the present invention. Although the golf club head300 shown in FIG. 3 shows a constant offset distance d1 across theentire perimeter of the striking face 302, the offset distance d1 mayvary to find the correct balance between weight removal and durabilitywithout departing from the scope and content of the present invention.

FIG. 4 of the accompanying drawings shows a cross-sectional view of agolf club head 400 in accordance with an exemplary embodiment of thepresent invention taken along cross-sectional line A-A′ shown in FIG. 3.The cross-sectional view of the golf club head 400 allows a clearer viewof the pocket 422 as well as the backing portion 423 of the centralportion 412 of the golf club head 400. Because the weight savingsachievable by the lightweight second material within the pocket 422needs to be balanced out with the strength and durability of themetallic material within the backing portion 423, the relativethicknesses of the pocket 422 and the backing portion 423 are importantto the current invention. In one exemplary embodiment of the presentinvention, the depth d2 of the pocket may be kept constant at greaterthan about 0.2 mm and less than about 2.0 mm, more preferably at greaterthan about 0.5 mm and less than about 1.5 mm, and most preferably atabout 1.0 mm. In order to balance out the durability sacrificed by theutilization of a lighter second material within the pocket 422, thebacking portion 423 may generally need to maintain a thickness d3 thatallows the golf club head 400 to endure the impact forces with a golfball. Hence, the thickness d3 of the backing portion 423 may generallyhave a constant thickness that is greater than about 1.5 mm and lessthan about 3.0 mm, more preferably greater than about 1.75 mm and lessthan about 2.75 mm, most preferably about 2.25 mm.

Despite the thicknesses articulated above, it should be noted that themore important number here is the ratio of the relative thicknessbetween the d2 and d3; which quantifies the relative thicknesses ofdepth d2 of the pocket 422 as well as the thickness d3 of the backingportion 423. This ratio, referred to as a “striking thickness ratio”within the context of this application, indirectly quantifies theability of the golf club head 400 to reduce unnecessary weight from thestriking face 402 while maintaining the durability of the striking face402. Striking thickness ratio, as referred to in this currentapplication, may more specifically be defined as the depth d2 of thepocket 422 divided by the thicknesses d3 of the backing portion 423shown below in Equation (2):

$\begin{matrix}{{{Striking}\mspace{14mu}{Thickness}\mspace{14mu}{Ratio}} = \frac{{depth}\mspace{14mu}( {d\; 2} )\mspace{14mu}{of}\mspace{14mu}{pocket}}{{thickness}\mspace{14mu}( {d\; 3} )\mspace{14mu}{of}\mspace{14mu}{backing}\mspace{14mu}{portion}}} & {{Eq}.\mspace{14mu}(2)}\end{matrix}$

The striking thickness ratio, as described above in this exemplaryembodiment, may generally be less than about 1.0, more preferably lessthan about 0.8, and most preferably less than about 0.7.

FIG. 5 of the accompanying drawings shows an enlarged cross-sectionalview of the circular region B shown in FIG. 4. More specifically, theenlarged view of the striking face 402 of the golf club head 400 shownin FIG. 5 allows a clearer view of relative thicknesses d3 and depth d2of the backing portion 423 and the pocket 422 respectively. In additionto the above, FIG. 5 also shows the face insert 520 being constructedout of a second material having a second density being removed from it'sresting place within the pocket 522. One of the first things torecognize about FIG. 5 is the relative size and shape of the face insert520 being reasonably similar to the size and shape of the pocket 522.Put it in another way, the face insert 520 may generally be designedwith a size and shape that allows it to fit within the pocket 522without departing from the scope and content of the present invention.More specifically, as it can be seen from FIG. 5, the thickness d2 ofthe face insert may generally be substantially similar to the depth d2of the pocket 522, illustrating the similarities.

Although minimally visible from FIG. 5, it is commonly known that thestriking face 502 portion of a modern day golf club head may generallyhave a slight curvature to help correct the adverse effects resultingfrom off center hits. This slight curvature of the striking face 502portion of the modern day golf club head may be more commonly known asthe bulge and roll of the golf club head, depending on whether the pointof reference is taken from the horizontal orientation or a verticalorientation. It is worth noting here that the thicknesses d2 of thestriking face 502 and/or the pocket 522 may generally be determined fromthe frontal surface of the striking face 502, meaning the pocket 522will have the same bulge and roll curvature as the front of the strikingface 502. Maintaining the bulge and roll curvature radius within thepocket 522 is advantageous to the durability of the striking face 502 ofthe golf club head, as a convex shaped surface will be able to absorbimpact forces better than a flat or even concave shaped pocket 522. Itshould be noted, however, the pocket 522 need not have a convex surfacein all embodiments to be within the scope and content of the presentinvention, the internal surface of the pocket 522 may be flat or evenhave a concaved shape, especially in situations where the striking face502 is already durable enough to absorb the impact forces.

The relative similar size and shape of the face insert 520 and thepocket 522 will generally help enhance the bonding of the face insert520 within the pocket 522. However, in addition to this pre-existingmechanical bond utilizing the geometry of the components, the bondbetween the face insert 520 and the pocket 522 could generally beenhanced with the usage of an adhesive type substance. Adhesive typesubstance, as discussed in this current application, may generally be asynthetic type adhesive; however, adhesive type substance may also be anatural adhesive, a contact adhesive, a trying adhesive, a hot meltadhesive, UV light curing adhesive, pressure sensitive adhesive, or anytype of adhesive capable of creating a chemical bond that holds the faceinsert 520 within the pocket 522 all without departing from the scopeand content of the present invention.

FIGS. 6, 6A, 6B, 6C, and 6D of the accompanying drawings shows furtheralternative embodiments of the present invention wherein the pocket 622may contain an undercut 628 around the perimeter engagement portion Cbetween the face insert 620 within the pocket 622 that further enhancesthe bond between the two above mentioned components. More specifically,FIGS. 6A, 6B, 6C, and 6D show enlarged views of various different typesof undercut 628 that could be used to enhance the attachment of the faceinsert 620 within the pocket 622 all without departing from the scopeand content of the present invention. Before going into more detailabout the various pockets 622 geometries, a brief discussion regardingthe method of inserting the face insert 620 into the pocket 622 havingsuch an undercut 628 will help explain the ingenuity of the currentinvention. Looking at FIGS. 6, 6A, 6B, 6C, and 6D, it can be seen thatit could be physically difficult to place the face insert 620 having alarger diameter past the undercut 628 into the pocket 622. Hence, inorder to place the face insert 620 into a pocket 622 that has anundercut 628, the composite material used to form the face insert 620may need to be placed in the pocket 622 before curing. Resin impregnatedmaterials, unlike metallic materials that have a rigid body, maygenerally have a pliable structure until the resin is cured. Hence, itcan be seen from above, if a composite type material is used toconstruct the face insert 620, the pliable nature of the compositematerial before curing allows the face insert to fit into the pocket622.

In addition to the pliable nature of the resin impregnated compositetype material used to construct the face insert 620, the multiple layersof fibrous material used to form the resin impregnated composite willalso allow the pocket 622 to be filled with the resin impregnatedcomposite around the undercut 628. More specifically, because resinimpregnated composite material is built by layering thin layers of resinfibers on top of one another, the various fibers layers can be filledinto the pocket 622 to get around the undercut 628 without departingfrom the scope and content of the present invention.

FIGS. 6A, 6B, 6C, and 6D all show different enlarged views of theperimeter engagement portion C allowing a clearer view of the variousundercut 628 geometries in accordance with various embodiments of thepresent invention. More specifically, FIG. 6A shows a V shaped undercut628 that helps secure the face insert 620 in the pocket 622. FIG. 6Bshows a V shaped undercut 628 with a flat portion near the external tipof the undercut 628 to eliminate sharp corners that could result inimpact high stress. FIG. 6C shows a further alternative embodiment ofthe present invention wherein a U shaped undercut 628 may be used tohelp secure the face insert 620 in the pocket 622. Finally, FIG. 6Dshows a further alternative embodiment of the present invention whereina U shaped undercut 628 has a flat tip to completely eliminate sharpcorners that could crack or break during impact.

At this point, it is worthwhile to recognize that having a pocket 622 atthe striking face 602 portion of the golf club head may offer additionalperformance benefits than what's immediately recognizable. Morespecifically, in addition to the obvious performance benefits that canbe achieved by creating more discretionary weight from this type ofgeometry shown above, utilizing this type of a pocket 622 will allow thegolf club head to maintain the a desirable acoustic sound. Acousticsound of a golf club head, although difficult to quantify, is somethingthat greatly influences the perceived performance of a golf club head.Because composite type materials may generally offer a very differentacoustic sound than a metallic type material, it may be important to thecurrent invention to adjust the acoustic sound of the golf club head tobe relatively similar to a golf club head having a completely metallicstriking face.

FIG. 7 of the accompanying drawings shows a signal power diagram of aprior art golf club head having a completely metallic striking face,illustrating the acoustic characteristics of a golf club head thatproduces a desirable sound. More specifically, FIG. 7 captures the power752 of the sound generated by the prior art golf club head as it impactsa golf ball as a function of the frequency 754. This power 752 andfrequency 754 may quantify the vibration of the various components ofthe golf club head such as the crown, sole, face, or any othercomplement of a golf club head as it impacts a golf ball. As we can seefrom FIG. 7, this prior art golf club head having a completely metallicstriking face may produce a first peak 756 in sound power 752 at about4,000 hertz. The peak 756 sound power 752, as shown in this currentprior art golf club head that has a completely metallic striking face,may generally have a total sound power output of about 0.2 watts. Hence,based on the above, it can be observed that a desirous sound of a golfclub head with a completely metallic striking face may have a first peakof power at a frequency that is greater than about 3,500 hertz, morepreferably greater than about 3,750 Hertz, and most preferably greaterthan about 4,000 Hertz.

FIG. 8 of the accompanying drawings shows a signal power diagram of aprior art golf club head having a completely composite striking face,illustrating the dramatic change in the acoustic sound characteristic ofsuch a type of golf club head. Right off the bat, one can see from FIG.8 the power of the sound produced by a prior art golf club head having acompletely composite striking face is significantly less than that of atraditional prior golf club head that has a metallic striking face.Although barely noticeable when plotted in the same scale as the diagramin FIG. 7, this completely composite prior art golf club head maygenerally have a first peak 856 in sound power 852 at about 3,000 hertz.The peak 856 sound power 852, as shown in this current prior art golfclub head having a completely composite striking face, may generallyhave a total sound power 852 output of less than about 0.002 watts.Hence, when compared to the signal power diagram of a prior art golfclub head having a completely metallic striking face shown in FIG. 7,one can see that completely replacing the striking face of a golf clubhead with composite material greatly sacrifices the desirable sound of agolf club head.

Turning now to FIG. 9 of the accompanying drawings we can see the signalpower diagram of a golf club head in accordance with the currentinvention. Even at an initial glance, it is immediately noticeable thatthe signal power diagram of the current invention more resembles thesignal power diagram of a prior art golf club head with a completelymetallic striking face shown in FIG. 7. More specifically, the signalpower diagram of the current inventive golf club head may have a firstpeak 956 in sound power 952 occurring at greater than about 3,500 hertzand less than about 4,500 hertz, more preferably greater than about3,750 hertz and less than about 4,250 hertz, and most preferably about4,000 hertz. The peak 956 sound power 952 of the current inventive golfclub head having a pocket at the striking face may yield a total soundpower 952 output of greater than about 0.1 watts, more preferablygreater than about 0.125 watts, most preferably about 0.15 watts.Because the signal power diagram of the current inventive golf club headshows significant similarities to the signal power diagram of a priorart golf club head with a completely metallic face, the acoustic soundof the current inventive golf club head is desirable despite having acomposite type face insert.

Because the desirability of the acoustic sound coming from the differentgolf club heads are dependent upon the above mentioned values within thesignal power diagram, it may be easier to quantify these values as arelationship to one another for ease of comparison. Equation (3) belowcreates a peak power to frequency ratio that captures the desirablesound of a golf club head in a way that is easily quantifiable.

$\begin{matrix}{{{Peak}\mspace{14mu}{Power}\mspace{14mu}{to}\mspace{14mu}{Frequency}\mspace{14mu}{Ratio}} = \frac{{Peak}\mspace{14mu}{Power}}{{Frequency}\mspace{14mu}{where}\mspace{14mu}{Peak}\mspace{14mu}{Power}\mspace{14mu}{Occurs}}} & {{Eq}.\mspace{14mu}(3)}\end{matrix}$

The peak power to frequency ratio of a golf club head in accordance withan exemplary embodiment of the present invention may generally begreater than about 2.5*10⁻⁵ watts/hertz and less than about 5*10⁻⁵watts/hertz, more preferably greater than about 3.0*10⁻⁵ watts/hertz andless than about 4.5*10⁻⁵ watts/hertz, and most preferably about 4.0*10⁻⁵watts/hertz.

Although the peak power to frequency ratio described above quantifiesthe acoustic sound of a golf club as it impacts a golf ball, it does nottake in consideration of the size of the golf club head. Because theacoustic sound of a golf club head may generally be caused by thevibration of the golf club head as it impacts a golf ball, the size ofthe golf club head is an important factor in determining the amount ofsurface area that is available for such a vibration when the golf clubhead is used to impact a golf ball. Hence, another important ratio torecognize in quantifying the sound of a golf club head may be the firstpeak frequency to volume ratio of a golf club head. Similar to thediscussion above describing what the desirable sound it, the golf clubhead in accordance with the current invention may generally have a firstpeak in frequency occurring within the range of greater than about 3,500hertz and less than about 4,500 hertz, more preferably greater thanabout 3,750 hertz and less than about 4,250 hertz, and most preferablyabout 4,000 hertz; as mentioned above. The golf club head in accordancewith the current invention may generally have a total volume of greaterthan about 400 cubic centimeters (cc) and less than about 500 cc, morepreferably greater than about 420 cc and less than 480 cc, and mostpreferably about 460 cc. Viewing the numbers above, the first peakfrequency to volume ratio relationship may generally be greater thanabout 7.0 hertz/cc and less than about 15.0 hertz/cc, more preferablygreater than about 9.0 hertz/cc and less than about 13.0 hertz/cc, mostpreferably about 8.0 hertz/cc. The first peak frequency to volume ratiois defined below as Equation (4).

$\begin{matrix}{{{First}\mspace{14mu}{Peak}\mspace{14mu}{Frequency}\mspace{14mu}{to}\mspace{14mu}{Volume}\mspace{14mu}{Ratio}} = \frac{{First}\mspace{14mu}{Peak}\mspace{14mu}{Frequency}}{Volume}} & {{Eq}.\mspace{14mu}(4)}\end{matrix}$

In addition to the weight savings from the striking face of the golfclub head and the improved acoustic performances described above, theutilization of a pocket that is filled with a second material having asecond density yields an additional advantage in creating a golf clubthat can hit a golf ball further by increasing the Characteristic Time(CT) of the golf club head. CT, as currently known in the golfingindustry, may generally relate to the amount of time a pendulum contactsthe striking face of a golf club head after being dropped from variousheight that simulates different velocities. The velocity and timevalues, captured by an accelerometer attached to the pendulum, are thengenerally plotted against a function of the velocity. A linear trendline having a specific slope may be formed by the various data points,and the ultimate y-intercept may yield the CT value of the golf clubhead. More details regarding the exact apparatus and procedure used toacquire the CT value of a golf club head may be found in U.S. Pat. No.6,837,094 to Pringle et al ('094 patent), the disclosure of which isincorporated by reference in its entirety.

FIG. 10 of the accompanying drawings shows a graphical representation ofthe various contact time results taken using the portable apparatus formeasuring the flexibility of the striking face of a golf club headaccording to the steps described in the '094 patent. More specifically,FIG. 10 shows the characteristic time results of the striking face of anexemplary golf club head in accordance with the current invention beingplotted on the y-axis against the velocities of the pendulum at each ofthe respective data points 1062 being plotted on the x-axis. It shouldbe noted that the velocities of the pendulum taken by an accelerometerattached to the pendulum is taken to an exponent value of −0.329 inorder to minimize the expected errors on the intercept value to create alinear relationship quantified by the Equation (5) below.

T=A+BV ^(−k)  Eq. (5)

Wherein T equals the time for the velocity of the pendulum to rise from5% to 95% of the maximum velocity recorded, B is the slope of thetrend-line 1064 formed by the various data points 1062, V is thevelocity of the pendulum test at the various data points 1062, and k isthe exponential adjustment factor to minimize the error in the interceptvalue of the golf club head. The intercept between the trend-line 1064and the y-axis, identified here as A, can be determined from the T, B,and V values above and may generally be the ultimate CT values used bythe USGA which correlates to the ability of the golf club head to flexduring impact with a golf ball.

It is worth noting here that, because the CT value here is determinedbased on the intercept A, the slope B of the trend-line 1064 formed bythe various CT results of each individual data point 1062 from thependulum test is an important factor that greatly affects the CT value.Because the current invention's utilizes a specific amount of compositethat has a lowered second density within the pocket at the striking faceportion of the golf club, the slope B of the trend-line 1064 created bythe various data points may generally be steeper than the slope of atraditional prior art golf club head. More specifically, the slopeformed from the trend-line 1064 of the various data points 1062 may beknown here at the “characteristic time slope”. The “characteristic timeslope”, as defined in the current invention above, may generally begreater than about 5 and less than about 50, more preferably greaterthan about 10 and less than about 45, even more preferably greater thanabout 12.5 and less than about 30, and most preferably greater thanabout 15 and less than about 20 as shown in FIG. 10. Although the unitsof the slope of the characteristic time slope trend-line 1064 is notspecifically discussed above, it can may generally be derived bydividing the units for the time in microseconds by the value of thevelocity to the −0.33 power. The end results of the unit for thetrend-line 1064 may generally be (microseconds/(seconds/meters)) or anyother simplified form of that equation all without departing from thescope and content of the present invention. More information regardingthe CT test, as defined and performed by the United States GolfAssociation (USGA), can be found in the Technical Description of thePendulum Test, Revised Version, Discussion of Points Raised DuringNotice & Comment Period (November 2003), the disclosure of which isincorporated by reference in its entirety.

Returning to our previous discussion regarding the various geometriesthat can be used to create the pocket within the striking face portionof the golf club head we now turn to FIG. 11. FIG. 11 of theaccompanying drawings shows a cross-sectional view of a golf club headhaving a pocket 1122 that may have a concave geometry. Although theconcave geometry may decrease the thickness of the backing portion 1123,the thinner back portion 1123 may offer additional deflection of theentire striking face 1102, which could result in an increase in theperformance of a golf club head. The thickness of the pocket 1122 maygenerally be shown in FIG. 11 as d3, which could vary from about 0.2 mmto about 3.5 mm all without departing from the scope and content of thepresent invention.

FIG. 12 of the accompanying drawings shows a cross-sectional view of agolf club head having a pocket 1222 in accordance with a furtheralternative embodiment of the present invention. More specifically, thebacking portion 1223 of this pocket 1222 may have a variable thickness,to promote a bigger sweet spot without affecting the geometry of theinsert 1220 within the pocket 1222. More detailed discussion on thebenefits of having a golf club head with a striking face that has avariable thickness may be found in U.S. Pat. No. 6,605,007 toBissonnette et al, the disclosure of which is incorporated by referencein its entirety. The backing portion 1223 in accordance with thisexemplary embodiment of the present invention may have two differentthicknesses d5 and d6, with the thicker portion d6 located near thecenter of the striking face 1202. Despite the above, numerous othervariations of this thickness profile with more distinct sections may beused all without departing from the scope and content of the presentinvention, so long as the backing portion has a variable thickness.Finally, it is worth noting that the thickness of the pocket 1222 andthe thickness of the face insert 1220 may all be substantially unchangedat a constant thickness of d2 also without departing from the scope andcontent of the present invention.

FIG. 13 of the accompanying drawings shows a cross-sectional view of agolf club head having a further alternative geometry for the pocket 1322and the face insert 1320 in accordance with a further alternativeembodiment of the present invention. More specifically, the face insert1320 in this exemplary embodiment of the present invention may have avariable thickness to improve the performance of the striking face 1302of the golf club head. In order to accommodate this variable thicknesson the face insert 1320, the backing portion 1323 may maintain aconstant thickness to accommodate the variable thickness of the faceinsert 1320. In order to maintain the constant thickness of the backingportion 1323, this alternative embodiment of the present invention maygenerally yield a backing portion 1323 that has a bend near the centralportion of the backing portion 1323 to match the thickened portion ofthe face insert 1320.

FIG. 14 of the accompanying drawings shows a cross-sectional view of agolf club head having a further alternative geometry for the pocket 1422as well as the face insert 1420 in accordance with a further alternativeembodiment of the present invention. More specifically, the face insert1420 in this exemplary embodiment of the present invention may have avariable thickness to improve the performance of the striking face 1420of the golf club head. The backing portion 1423, provides an alternativeway to provide support to the face insert 1420 in providing a variablethickness that gets thinner at the central portion of the striking face1402. This embodiment may be preferred to provide more flexuralstiffness of the central portion as a thinner central portion mayprovide more deflection.

FIG. 15 of the accompanying drawings shows a cross-sectional view of agolf club head having a further alternative geometry for the pocket 1522as well as the face insert 1520 in accordance with a further alternativeembodiment of the present invention. More specifically, this embodimentof the of the present invention will have a backing portion 1523 thathas an increased thickness at the central portion of the striking face1502 to increase the durability of the golf club head. Hence, in orderto accommodate the increased thickness of the backing portion 1523 atthe central portion of the striking face 1502, the thickness of the faceinsert 1520 may generally be thinner at central portion. This embodimentmay be preferred in situation where the durability of the golf club headneeds to be improved.

FIG. 16 of the accompanying drawings shows a cross-sectional view of agolf club head utilizing a different geometry to form the striking face1602 in accordance with a further alternative embodiment of the presentinvention. More specifically, the backing portion 1623 forms a thinnerbut still complete striking face 1602, only to have it covered by theface insert 1620. This face insert 1620, although not conventional insize, serves the same purpose of removing unnecessary weight away fromthe striking face 1602 portion of the golf club head. This embodiment ofthe present invention provides advantages over prior art golf club headsin that it removes unnecessary weight away from the striking face 1602of the golf club head while maintaining the structural integrity of thebacking portion 1623 without departing form the scope and content of thepresent invention.

FIG. 17 of the accompanying drawings shows a cross-sectional view of agolf club head utilizing a slightly different geometry to form thestriking face 1702 in accordance with a further alternative embodimentof the present invention. More specifically, this embodiment of thepresent invention will utilize two separate backing portions 1723 atopposite ends of the striking face 1702 leaving face insert 1720unsupported at the central region. This alternative embodiment of thepresent invention may help completely eliminate the weight that'sassociated with a full backing portion 1723, further reducing theunnecessary weight associated with the striking face 1702 of the golfclub head.

FIG. 18 of the accompanying drawings shows a cross-sectional view of agolf club head utilizing a different geometry to form the striking face1802 in accordance with a further alternative embodiment of the presentinvention. This embodiment of the present invention shown in FIG. 18, inorder to remove shift the bonding points away from the impact portion ofthe striking face 1802, has shifted the perimeter of the face insert1820 towards the crown and sole portion of the golf club head. The shiftof the bonding points away from the striking face 1802 is beneficial tothe performance of the golf club head in that it moves the joints awayfrom the points of the highest stress, decreasing the bonding strengthrequired. As it can be seen from FIG. 18, the backing portion 1823 hasbeen shifted towards the crown and sole portion of the golf club head toachieve this objective without departing from the scope and content ofthe present invention.

FIG. 19 of the accompanying drawings shows a cross-sectional view of agolf club head utilizing a different geometry to form the striking face1902 in accordance with a further alternative embodiment of the presentinvention. More specifically, as it can be seen from FIG. 19, the faceinsert 1920 may wrap around the entire striking face 1902 of the golfclub head to shift the joints away from the striking surface of the golfclub head. However, the golf club head shown in FIG. 19 provides anadditional performance advantage in that the metallic backing portionwraps around to provide partial backing support for the face insert1920. In addition to the above features, the face insert 1920 shown inthis current exemplary embodiment of the present invention may utilize athickened central portion to improve the size of the sweet spot withoutdeparting from the scope and content of the present invention.

It is worth noting here that the golf club heads shown FIGS. 17-19 are alittle different from the earlier discussion of the various embodimentsof the present invention in that the pockets created by the golf clubsshown in FIGS. 17-19 do not have a backing portion. In situations wherethe pocket is supported by a metallic backing portion, the major causeof failure within the various plies of composite type material may bedue to the delamination of the individual plies of composite fiber.However, in situations where the pocket is not supported by a backingportion, the major concern becomes the durability of the compositematerial itself, making the strength and durability of the compositetype material a major concern. Despite the fact that almost any kind ofresin impregnated carbon fiber may provide significant weight savingsbenefits, not all types of resin impregnated carbon fiber can meet thedurability requirements needed to be used in a golf club head. In orderto understand the different types of resin impregnated carbon fiber, itmay be helpful to turn to FIG. 20 of the accompanying drawing showing astress and strain chart 2000 of the fibers within the carbon fiberimpregnated fiber that helps illustrate the relationship between thestress and the strain values of such a resin impregnated carbon fibermaterial that may be suitable for use as the second material inaccordance with the present invention.

First and foremost, looking at the stress and strain chart 2000, we cansee that the stress and strain relationship 2030 of the fibers of thiscomposite type material may have linear elastic to failurecharacteristic. Linear elastic to failure characteristic in the fiber ofa composite material may generally be more preferable than non-linearelastic to failure in that it allows for purely elastic deformation thatdoes not alter the physical dimensions of the composite material. Thistype of purely linear elastic to failure characteristic in the fibers ofthe composite is more preferable than non-elastic elastic to failurebecause a brittle fiber that has a linear elastic to failure maygenerally yield a higher ultimate tensile strength than the yield stressachievable by a brittle fibers that exhibits non-linear elastic tofailure characteristics. In addition to showing the linear elastic tofailure characteristic of the fiber of the composite material, thestress and strain relationship 2030 of FIG. 20 also shows the strengthand modulus of an ideal fiber for the composite material used for thecurrent invention. More specifically, FIG. 20 shows that the fibers ofthe composite material used may generally have a tensile strength ofgreater than about 4.0 Gpa and less than about 6.0 GPa, more preferablygreater than about 4.5 GPa and less than about 5.5 GPa, and mostpreferably about 4.9 GPa. Paired with the tensile strength articulatedabove, the composite material may generally have a tensile modules ofelasticity, determined by the slope of the stress and strainrelationship 2030, of greater than about 200 GPa and less than about 300GPa, more preferably greater than about 225 GPa and less than about 275GPA, and most preferably about 241 GPa. It is worth noting here thatalthough the tensile strength and tensile modulus are all importantcharacteristics of the fibers of the composite material, the keydeterminant on what makes the fiber suitable for the current inventionwill hinge on the strain to failure percentage. The strain to failurepercentage, as referred to in the current exemplary embodiment, maygenerally be defined as the tensile strength of the fiber divided by thetensile modulus of elasticity of the fiber, as more specificallyarticulated in Equation (6) below.

$\begin{matrix}{\frac{{Tensile}\mspace{14mu}{Strength}}{{Tensile}\mspace{14mu}{Modulus}\mspace{14mu}{of}\mspace{14mu}{Elasticity}} = {{Strain}\mspace{14mu}{to}\mspace{14mu}{Failure}\mspace{14mu}{Percentage}}} & {{Eq}.\mspace{14mu}(6)}\end{matrix}$

The strain to failure percentage, as shown in the current exemplaryembodiment in FIG. 20, and based on the tensile strength and tensilemodulus of elasticity number above, may generally be greater than about1.0% and less than about 10.0%, more preferably greater than about 2.0%and less than about 8.0%, and most preferably about 2.5%.

Continuing the discussion about utilizing a composite material to formthe face insert, FIG. 21 of the accompanying drawings shows an explodedview of a composite face insert 2120 in accordance with an exemplaryembodiment of the present invention. More specifically, the explodedview of the face insert 2120 allows a better view of how the variousorientations of the fiber within the composite face insert 2120 may bealtered to affect the performance characteristics of the golf club head.The face insert 2120 shown in FIG. 21 may generally have a first layer2141, a second layer 2142, a third layer 2143, a fourth layer 2144, afifth layer 2145, a sixth layer 2146, a seventh layer 2147, an eightlayer 2148, or any number of layers deemed to be needed to construct theface insert 2120 all without departing from the scope and content of thepresent invention. In this current exemplary embodiment shown in FIG.21, the face insert 2100 may have eight different layers, 2141, 2142,2143, 2144, 2145, 2146, 2147, and 2148, each with a fiber orientated ina different orientation than the layer it immediately engages. Morespecifically, first layer 2141 may have the fibers orientated in ahorizontal direction labeled as 0 degrees for ease of reference. Secondlayer 2142 may follow the first layer 2141 with fibers orientated in adiagonal direction more easily identified as +45 degrees. Third layer2143 may follow the second layer 2142 with fibers orientated in avertical direction more easily identified as 90 degrees. Fourth layer2144, may follow the third layer 2143 with another layer of fibersorientated in a diagonal direction different from the second layer 2142,more easily identified as −45 degrees. Although eight different layersare shown in FIG. 21, subsequent layers 2145, 2146, 2147, and 2148 inthis exemplary embodiment may follow the same orientation as the firstfour layers. In fact, any additional number of layers may be added inaddition to what is shown in FIG. 21 to reach the required thicknesswithout departing from the scope and content of the present invention,so long as it follows the structure set forth above in FIG. 21. Havingthis type of orientation may yield a composite face insert 2120 that hasquasi-isotropic properties resulting in a face insert 2120 that issufficiently strong enough to be able to withstand loads orientated innumerous different directions without failing.

FIG. 22 of the accompanying drawings shows a further alternativeembodiment of the present invention wherein the face insert 2220 exhibitanisotropic properties. Anisotropy, as used in this current exemplaryembodiment, refers to the directionally dependent strength of thecomposite face insert 2220 that results from the uniform orientation ofthe fibers within the composite face insert 2220. More specifically, asit can be seen from FIG. 22, the first layer 2241, the second layer2242, the third layer 2243, the fourth layer 2244, the fifth layer 2245,the sixth layer 2246, the seventh layer 2247, and the eighth layer 2248may all have fibers that run in a substantially vertical direction thatis more easily identified as the 90 degree direction. Having ananisotropic composite face insert 2220 may further improve theperformance of a golf club head by focusing the strength of the faceinsert 2220 along a direction that is subjected to the most stress whilesacrificing some strength along other directions that tends to notgenerate as much stress. Within the design space of a golf club head,the majority of the stress is generated in a crown-sole direction;hence, by orienting the orientation of the fiber along that oppositedirection, the striking face will have an increased modulus in thedirection that has the shortest distance to absorb this stress. FIG. 22only shows eight layers of fiber within the composite face insert 2220for illustration purposes, however, it should be noted that additionallayers may be added to the face insert 2220 to reach the desiredthickness of the face insert 2220 without departing from the scope andcontent of the present invention so long as it follows the structure setforth above in FIG. 22.

In addition to the increased modulus along the desired direction, theface insert 2220 shown in FIG. 22 may also offer an additionalperformance benefit by reducing the number of plies of composite neededin the less stressed direction that spans from crown to sole, furtherremoving unnecessary weight from the striking face of the golf clubhead. It should be noted here that although the current discussionrelates more specifically to a composite based material being used forthe face insert 2220, the same concept of anisotropy may apply tometallic materials such as aluminum, magnesium, or even titanium allwithout departing from the scope and content of the present invention.More detailed discussion regarding the creation and the use of metallicanisotropy materials may be found in U.S. Pat. No. 6,623,543 to Zelleret al., the disclosure of which is incorporated by reference in itsentirety.

FIG. 23 of the accompanying drawings shows a further alternativeembodiment of the present invention wherein a different combination offiber orientations yielding a face insert 2320 that isquasi-anisotropic. Quasi-anisotropy, as used in this current exemplaryembodiment, refers to the directionally dependent strength of thecomposite face insert 2320 that results from an orientation of thecomposite fibers that favors one orientation over another orientation.More specifically, face insert 2320 may have a first layer 2341 withfibers orientated substantially vertical direction that is more easilyidentified as a 90 degree direction. Positioned behind the first layer2341 is the second layer 2342 with fibers orientated in a substantiallydiagonal direction more easily identified as +45 degree. Third layer2343, being placed behind the second layer 2342 may have its fibersorientated that are similar to the fiber orientation of first layer 2341being substantially vertical, reinforcing the strength of the faceinsert 2300 along the crown-sole orientation. Behind the third layer2343 is a fourth layer 2344 having its fibers orientated in asubstantially opposite diagonal direction than that of the second layer2342. The fourth layer 2344 may have fibers at a −45 degree orientation,signifying that its fiber orientation is perpendicular to that of thesecond layer 2342. The fifth layer 2345, placed behind the fourth layer2344, may have its fibers return to a substantially vertical orientationto further increase the strength of the face insert 2320 in the crownsole orientation. The sixth layer 2346, as shown in the currentexemplary embodiment, may generally have fibers orientated in ahorizontal direction that can more easily identified as being at 0degrees. Finally, the seventh layer 2347 of the composite face insert2320 may revert back to having its fiber in the substantially verticaldirection to further reinforce the strength along the heel toedirection.

The face insert 2320 shown in FIG. 23 may generally combine thequasi-isotropic benefits of the face insert 420 shown in FIG. 21 withthe anisotropic benefits of face insert 520 shown in FIG. 22. Morespecifically, because the face insert 2320 shown in FIG. 23 has fibersalong several different orientations, it may help preserve the flexuralstiffness of the face insert 2320 across various directions. However,having a increased number of layers that have fibers running in thevertical orientation allows the face insert 2320 shown in FIG. 23 tohave increased the flexural stiffness of the face insert 2320 across themost heavily stressed direction. Once again, it should be noted thatalthough FIG. 23 only shows seven layers of composite fibers, numerousother numbers of layers may be used so long as it follows the structureset forth above in FIG. 23.

It should be noted that although FIGS. 5, and 11-19 all show distinctfeatures and geometries for the face insert in combination with theirrespective backing portion having their own distinct features andgeometries, the various features and geometries of the variouscomponents can be interchanged to create different designs and achievedifferent goals all without departing from the scope and content of thepresent invention.

FIG. 24 of the accompanying drawing shows an exploded cross-sectionalview of a golf club head 2400 in accordance with an alternativeembodiment of the present invention taken across cross-sectional lineA-A′ in FIG. 3, wherein the face insert 2420 is placed behind the innersurface of a thinner striking face 2402 to form a face backing layer2420. More specifically, FIG. 24 shows a golf club head 2400 beingformed out of a hollow unitary shell 2401 with an opening 2450 at acrown portion of the golf club head 2400. This specific type of geometryhaving an opening 2450 near a crown portion of the golf club head 2400may generally be known as a “crown pull” construction in the golfindustry, as the casting process will involve an insert that is pulledout from the crown portion of the golf club head 2400 to create theopening 2450. However, the opening 2450 may be machined withoutdeparting from the scope and content of the present invention, so longas there is an opening 2450 near the crown portion of the golf club head2400.

The golf club head 2400 shown in FIG. 24 is also shown with a panel 2452configured to cover the opening 2450 to complete the golf club head2400. In one exemplary embodiment, the panel 2452 may be formed out ofthe same material as the hollow unitary shell 2401 to preserve theacoustic characteristics of the golf club head 2400; however, numerousother materials may also be used without departing from the scope andcontent of the present invention, so long as the panel 2452 is capableof covering the opening 2450.

Face backing layer 2420, as shown in this current exemplary embodimentof the present invention, may generally be attached to the rear surfaceof the thinner striking face 2402 portion of the golf club head 2400 toprovide some structural rigidity lost by the thinning of the strikingface 2402. Similar to the prior discussions, the replacement of thestriking face 2402 with a lightweight material of the face backing layer2420 will reduce the overall weight of the striking face portion 2402,creating more discretionary weight. Based on the above rationale, thesecond material used to form the face backing layer 2420 may generallyhave a second density that is lower than the first density of a firstmaterial used to create the hollow unitary shell 2401; resulting in theweight savings described above. In fact, the density of the secondmaterial may be may be less than about 2.7 g/cm³ if aluminum is used,less than about 1.738 g/cm³ if magnesium is used, and less than about1.70 g/cm³ if composite type material is used. In one preferredembodiment of the present invention, the material for the face backinglayer 2420 may be a carbon fiber based composite type material for it'shigh strength and low mass properties.

Because a thinned striking face 2402 may lose a significant amount ofstructural rigidity, in order for the golf club head 2400 to survive theimpact with a golf ball, the face backing layer 2420 needs to replacethe amount of structural rigidity that is lost. In addition to thereplacement of the structural rigidity, the addition of the face backinglayer 2420 may also serve to distribute the impact load away from thelocalized impact location. Hence, because of the features provided bythe face backing layer 2420 above, the thinned striking face 2402 maygenerally have a thickness of between about 0.25 mm to about 3.00 mm,more preferably between about 0.25 mm to about 1.00 mm, most preferablybetween about 0.25 mm to about 0.45 mm, all of which is significantlythinner than what the previous durability standards would require. Onthe flip side, the face backing layer 2420 may generally have athickness of between about 0.5 mm to about 4 mm, to provide thestructural rigidity needed to support the newly thinned striking face2402.

Although not specifically shown in FIG. 24, it is generally desirable tocover a significant amount of the internal back surface of the strikingface 2402 with the face backing layer 2420, as a higher percentage ofcoverage will equate to a higher structural support that can be providedby the face backing layer 2420. In one exemplary embodiment, the facebacking layer 2420 covers greater than about 90% of the internal backsurface of the striking face 2402, more preferably greater than about95%, and most preferably the face backing layer 2420 covers 100% of theinternal back surface of the striking face 2402.

Finally, it is worth noting here that the face backing layer 2420 maygenerally extend into both the crown portion and the sole portion of thegolf club head 2400 to provide better structural rigidity and contactsurface, increasing the ability of the face backing layer 2420 tostrengthen the thinned striking face 2402 without having to add too muchunnecessary weight. Although the exact distance of the extension portionis not critical, the length of the extension 2454 may generally begreater than about 3.00 mm, more preferably greater than about 5.00 mm,and most preferably greater than about 7.00 mm, all without departingfrom the scope and content of the present invention. The length of theextension 2454 may generally be measured from the plane the portion ofthe face backing layer 2420 that has completely transition onto theeither the crown portion or the sole portion in order to accuratelydetermine the length of the extension 2454. Alternatively speaking, thelength of the extension 2454 begins at the point where the face backinglayer 2420 forms a planar surface that is substantially perpendicular tothe striking face plane.

Based on the construction disclosed above, the attachment of the facebacking layer 2420 may generally be accomplished using a bladder moldingprocess. The bladder molding process is a common process used to attachcomposite material to an internal wall of a golf club head by using anexpandable bladder to create unique geometries. More specifically, thebladder molding process may generally involve the steps of inserting aninflatable bladder into the golf club head via an opening, inflating thebladder until at least a portion of the bladder pushes upon the facebacking layer. Alternatively, speaking, the bladder applies sufficientpressure to the composite face backing layer such that it juxtaposesitself against the internal back surface of the golf club head. Finally,once the composite face backing layer is sufficiently attached to theinternal surface of the striking face via conventional bondingprocesses, the bladder is deflated to allow it to be extracted from thegolf club head via the opening. More information regarding the bladdermolding process can be found in a commonly owned U.S. Pat. No. 7,281,991to Gilbert et al., the disclosure of which is incorporated by referencein its entirety.

FIG. 25 of the accompanying drawings shows an exploded cross-sectionalview of a golf club head 2500 in accordance with a further alternativeembodiment of the present invention taken across cross-sectional lineA-A′ in FIG. 3, that incorporates an opening 2550 near a sole portion ofthe golf club head 2500. Similar to the discussion above, the opening2550 is part of the hollow unitary shell 2501 and this type ofconstruction shown in FIG. 25 may generally be known as a “sole pull”;as the casting process will involve an insert that is pulled out fromthe sole portion of the golf club head 2500 to create the opening 2550.However, the opening 2550 may be machined without departing from thescope and content of the present invention, so long as there is anopening 2550 near the sole portion of the golf club head 2500. Similarto the above, the face backing layer 2520 attaches to an internal backsurface of the striking face 2502 of the golf club head to providestructural support for the thinned striking face 2502.

FIG. 26 of the accompanying drawings shows an exploded cross-sectionalview of a golf club head 2600 incorporating an opening 2650 at both thecrown and the sole portion of the golf club head 2600 taken acrosscross-sectional line A-A′ in FIG. 3. The golf club head 2600 is stillcreated using a hollow unitary shell 2601, with the panels 2652 coveringthe crown and sole openings 2650. In this current exemplary embodiment,the bladder used for bladder molding process can be inserted througheither the crown opening 2650 or the sole opening 2650 to provide theinternal structure to set the face backing layer 2620 without departingfrom the scope and content of the present invention.

In a further alternative embodiment of the present invention, golf clubhead 2600 could be formed with a face cup type geometry at the strikingface 2602 portion of the golf club head 2600, eliminating the need for abladder mold. However, the creation and attachment of the face backinglayer 2620 in a face cup geometry will still require pressure to beapplied to the face backing layer 2620 to allow the composite materialto settle and form without departing from the scope and content of thepresent invention.

Lastly, FIGS. 27-1 show enlarged cross-sectional views of the strikingface portion of the golf club head as shown in circle B in FIG. 26;allowing the variable face geometry to be created to increase the sizeof the sweet spot. Without duplicating the discussion above regardingthe benefits of variable face geometry, it is worthwhile to note herethat the variable face geometry could be accomplished by variousthicknesses in both the actual thinned striking face as well as the facebacking layer.

FIG. 27 shows one embodiment of the present invention wherein thethinned striking face 2702 and the face backing layer 2720 is held at aconstant thickness. In this specific geometry, the change in flexuralstiffness of the striking face 2702 could be accomplished by varying themodulus of the composite fibers of the face backing layer 2720 toachieve that variation without actually adjusting the thickness.

FIG. 28 shows another embodiment of the present invention wherein thethinned striking face 2802 has a constant thickness while the facebacking layer 2820 has a variable thickness. Ultimately, specificembodiment creates different flexural stiffness at different parts ofthe golf club head to improve the size of the sweet spot of the golfclub head without departing from the scope and content of the presentinvention.

FIG. 29 shows another embodiment of the present invention wherein thethinned striking face 2902 has a variable thickness and the face backinglayer 2920 has a constant thickness, allowing it to change shape withthe contours of the thinned striking face 2902.

FIG. 30 shows another embodiment of the present invention wherein thethinned striking face 3002 has a variable thickness while the facebacking layer 3020 also has a variable thickness, creating what appearsto be a constant thickness at the internal back surface of the facebacking layer 3020.

FIG. 31 of the accompanying drawings shows a cross-sectional view of agolf club head 3100 in accordance with an even further alternativeembodiment of the present invention taken across cross-sectional lineA-A′ in FIG. 3; wherein a backing layer 3120 is placed behind the innersurface of a thinner striking face 3102. In this embodiment, the facebacking layer 3120 may generally be made out of a composite material,reinforcing the structural rigidity of the striking face 3102. Thisincrease in structural rigidity allows the actual thickness of thetitanium material used in the striking face 3102 to be reduced, removingunnecessary mass from the overall club head itself. It should be notedthat in this exemplary embodiment, the composite backing layer 3120 hasa flange portion that form the extensions 3154 to help increase the bondbetween the backing layer 3120 and the striking face 3102. It should benoted that the extensions 3154 in this embodiment terminates short ofthe ends of the actual striking face 3102 portion, exposing the titaniummaterial to the unitary body shell 3101 to the unitary body shell 3101.This exposure of the titanium striking face 3102 to the titanium unitarybody shell 3101 is crucial to the present embodiment because it allowsthe two components to be welded together without the need for additionalbonding. In this current exemplary embodiment, the striking face 3102and the unitary body shell 3101 are welded together at a face to bodyjoint 3160. The face to body joint 3160 may generally be placed awayfrom the striking plane of the golf club head 3100 in order to removejoints at high stress locations. In one exemplary embodiment of thepresent invention, the face to body joint 3160 may be placed at adistance d4 of greater than about 10 mm away from the striking face3102, more preferably greater than about 12.5 mm away from the strikingface 3102, and most preferably greater than about 15 mm away from thestriking face 3102. Alternatively speaking, the return portion of thestriking face 3102 may have a distance d4.

FIG. 32 of the accompanying drawings shows a cross-sectional view of agolf club head 3200 in accordance with a further alternative embodimentof the present invention. In this alternative embodiment of the presentinvention, the backing layer 3220 that is generally made out of acomposite type material may extend pass the face return into the faceand body joint 3260 portion of the golf club head to connect the frontalstriking 3202 to the unitary shell body 3201. It should be noted that inthis exemplary embodiment, the face to body joint 3260 may utilize a lapjoint instead of the traditional butt joint shown in earlier embodimentsof the present invention. To further illustrate the face to body joint3260, an enlarged cross-sectional view of circular region C is providedin FIG. 33.

FIG. 33 of the accompanying drawing shows an enlarged cross-sectionalview of the face and body joint 3360 together with the striking face3302 as well as the backing layer 3320. Here, in this enlarged view itcan be seen that the backing layer 3320 may be used as part of the lapjoint construction to join together the different parts of the golf clubhead. Having a lap joint at the face and body joint 3360 portion may bepreferred over butt joints, as the lap joints may help furtherdistribute the impact stresses of the golf club head with a golf ball.Moreover, because the backing layer 3320 may generally be comprised outof a composite type material, the directional strength of the compositecan be designed into the construction to improve the bond strength.

In addition to illustrating the lap joint construction of the face tobody joint 3360, FIG. 33 of the accompanying drawings also illustratethe thickness d8 of the return portion of the striking face 3302. Inorder to maintain a more flexible joint to further eliminate thestresses associated with a golf ball impact, the thickness d8 of thereturn portion of the metallic striking face 3302 may generally be lessthan about 0.1 mm, more preferably less than about 0.8 mm, and mostpreferably less than about 0.7 mm to create a flexible joint. Thecreation of such a flexible joint may not only help eliminate stressraisers at the face to body joint 3360, but could also improve theperformance and compliance of the striking face 3302 itself by allowingthe striking face 3302 to flex more upon impact with a golf ball.

Another interesting feature of the present invention shown in FIG. 33worth highlighting is the elimination of any hard step and junctions atthe face to body joint 3360 portion of the golf club head. As previouslymentioned, this face to body joint 3360 may generally be subjected tohigh stress when impacting a golf ball, hence the elimination of anyhard step and junctions of that sort will eliminate any issuesassociated with increased stress of the face to body joint 3360.

FIG. 34 of the accompanying drawings shows an enlarged cross-sectionalview of a striking face 3402 portion of the golf club head in accordancewith a further alternative embodiment of the present invention. Morespecifically, in this embodiment, the crown face to body joint 3461 andthe sole face to body joint 3462 may be placed at different distancesfrom the striking face 3402. In this embodiment, the crown face to bodyjoint 3461 distance d9 may generally be greater than about 25 mm, morepreferably greater than about 27.5 mm, and most preferably about 30 mm.Alternatively speaking, distance d9 may also refer to the crown returnportion of said striking face 3402. While, the distance of the sole faceto body joint 3462 may maintain the same distance d4 of greater thanabout 10 mm away from the striking face 3102, more preferably greaterthan about 12.5 mm. It should be noted that in this exemplaryembodiment, the distance of d4 is always less than the distance d6 inorder to create the difference in the stress levels between the crownand sole portion of the golf club head. In order to further illustratethis difference in crown face to body joint 3461 location, a top view ofthe golf club head is provided in FIG. 35.

FIG. 35 of the accompanying drawings shows a top view of a golf clubhead 3500 in accordance with the alternative embodiment of the presentinvention shown in FIG. 34. More specifically, this view allows theshape and geometry of the crown face to body joint 3561 to be shown moreclearly. In addition to illustrating the distance d9 depth of the offsetfrom the striking face 3502, FIG. 35 also shows the width d10 of theoffset face to body joint 3561 at the central portion of the crown ofthe golf club head 3500. In the current exemplary embodiment, the widthd10 may generally be between about 40 mm and about 60 mm, morepreferably between about 45 mm and about 55 mm, and most preferablyabout 50 mm. The rationale behind only recessing the central crownportion of the face to body joint 3561 is because that portion of thegolf club head may generally experience the highest level of stressduring impact with a golf ball. However, in other embodiments, therecess could occur at the sole portion, the heel portion, the toeportion, or any combination thereof to address the specific high stresslevels all without departing from the scope and content of the presentinvention.

FIG. 36 of the accompanying drawings shows a flow chart diagramillustrating a method of manufacture in accordance with an exemplaryembodiment of the present invention. In step 3601 one or more layers ofcomposite material is placed behind the striking face of a golf clubhead within an internal cavity portion of the striking face portion. Inthis initial step, the layers of composite material may generally havean overall thickness of less than about 3.1 mm, more preferably lessthan about 3.0 mm, and most preferably less than about 2.9 mm. Inaddition to the thickness, the fiber orientation of the one or morecomposite layers is also important to the proper functionality of thepresent invention.

In one preferred embodiment of the present invention, composite materialbehind the striking face portion may be formed of a multiple sheets of0.1 mm prepreg composite in a patterned stacking sequence of (90°,67.5°, 45°, 22.5°, 0°, −22.5°, −45°, −67.5°) repeated three timescombined with one of each layer at the following orientations (90°,67.5°, 45°, 22.5°, and 0°). Alternatively speaking, the composite layerwill have the following number of fibers in each orientation: 90°—fourplies, 67.5°—four plies, 45°—four plies, 22.5°—four plies, 0°—fourplies, −22.5°—three plies, −45°—three plies, and −67.5°—three plies) fora total of 29 plies. In an alternative embodiment of the presentinvention, the one or more layers of composite face insert could have atotal thickness of between about 27 plies to about 31 plies, morepreferably between about 28 plies to about 30 plies, most preferablyabout 30 plies, all without departing from the scope and content of thepresent invention. It should be noted that reference to angles used todetermine fiber orientation above is based off a circular patternlooking at the frontal portion of the golf club striking face, wherein0° is shown horizontally in the heel direction of the golf club strikingface.

As a result of the orientation described above, it can be said that in apreferred embodiment, the one or more layers of composite materialcomprises more layers in a positive orientation than in a negativeorientation.

Illustrating the processes involved in step 3601, FIG. 37 shows anenlarged cross-sectional view of the striking face portion of a golfclub head in accordance with this alternative embodiment of the presentinvention. In fact, FIG. 37 also illustrates the process involvedwherein the one or more layers of composite material are partially curedin step 3603 while an axial force is applied in the direction of thestriking face.

FIG. 37 shows an enlarged cross-sectional view of a golf club headhaving a striking face portion 3702 as well as a composite face insert3720 placed behind the striking face portion 3702. It should be notedthat in this current exemplary embodiment, the striking face portion3702 may have a return portion 3783, creating a “C” shaped striking faceportion 3702. It can be seen in FIG. 37 that when an axial force 3784 isapplied to the one or more layers of composite face insert 3720 behindthe striking face portion 3702 via a die 3782, the uni-directional forceis not applied in alternate directions such as the return 3783 portionof the striking face 3702. If this was the only step used to ensureproper bonding between the two components, a separation is likely tooccur between the striking face portion 3702 and the composite faceinsert 3720 at or around the return 3783 portion. Alternativelyspeaking, it can be said that the axial force 3784 is applied only in adirection that is perpendicular to a loft of the striking face 3702 inthis step of the method.

Referring back to step 3605 shown in FIG. 36, the present inventionintroduces a bladder to put behind the composite material, allowing thebladder to distribute the stress more evenly across multiple surfaces.FIG. 38 illustrates the introduction of the bladder 3886 behind the oneor more layers of composite face insert 3820 in its inflated state. Inthe current inflated state, the bladder 3886 could deform if subjectedto any pressure or force, allowing it to conform to the contours of theone or more layers of composite face insert 3820 backing layer. In oneexemplary embodiment of the present invention, the bladder 3886 isgenerally filled with an inert gas such as nitrogen or argon. However,in alternative embodiments of the present invention, the bladder 3886may be filled with any type of fluid capable of conforming to thecontours of the golf club head without departing from the scope andcontent of the present invention.

Referring back to FIG. 36, we can see that subsequent to step 3605, step3607 utilizes a tool to apply pressure to the bladder to cause thebladder to deform to match the contours of the internal portion of thecomposite material face insert. This step is illustrated more clearly inFIG. 39. FIG. 39 of the accompanying drawings shows an enlargedcross-sectional view of an intermediary step used to create the golfclub head. In this step, a die 3982 is introduced by applying an axialforce 3984 on the bladder 3986 itself in the direction that isperpendicular to the loft of the striking face 3902 portion. Once thedie 3982 is introduced, step 3609 of FIG. 36 illustrates the finalcuring process and the application of hydrostatic force. The hydrostaticforce actually stems from an application of axial force 3984 by the die3982 onto the bladder 3986 instead of on the composite material faceinsert 3920 itself. This hydrostatic force will apply pressure inmultiple directions onto the one or more layers of composite materialface insert 3920, creating a stronger bond between the compositematerial face insert 3920 and the striking face 3902. Alternativelyspeaking, the bladder 3986 applies a hydrostatic force in one or moredirections to said one or more layers of composite. In one preferredembodiment, the bladder 3986 allows a uniform pressure to be applied toall portions of the one or more layers of composite insert 3920;however, in alternative embodiments of the present invention multiplebladders could be used to create specific pressure at differentlocations of the composite insert 3920 also without departing from thescope and content of the present invention.

FIG. 40 shows an enlarged cross-sectional view of the striking faceportion of a golf club head in accordance with the alternativeembodiment of the present invention. In this embodiment of the presentinvention, the backing portion 4023 creates a backstop for the strikingface portion, and in this specific embodiment of the present invention,requires the striking face portion to be attached to the body portionvia a bonding process that utilizes adhesive. However, in alternativeembodiments of the present invention, the bonding process could utilizea mechanical lock process, welding process, or even brazing processwithout departing from the scope and content of the present invention.

FIG. 41 shows an enlarged cross-sectional view of circular region Bshown in FIG. 4 of a golf club head in accordance with a furtheralternative embodiment of the present invention. In this embodiment ofthe present invention, we can see that the face insert 620 may generallycreate a dovetail type undercut 4128 around the perimeter engagementportion C between the face insert 4120 within the pocket 4122 thatfurther enhances the bond between the two above mentioned components.However, this specific undercut differs from prior embodiments discussedin FIGS. 6, 6A, 6B, 6C, and 6D in that it has a specific shape, angle,and geometry that significantly enhances the ability of the pocket 4122to retain the face insert 4120 without sacrificing the performance ofthe golf club head 4100 itself.

It should be noted here that the thickness d2 of the face insert 4120and the thickness d3 of the backing portion 4123 are similar to theprevious discussions, thus establishing a Striking Thickness Ratio alsoin line with the previous discussions. In summary, the thickness d2 ofthe face insert 4120 may generally be between 0.2 mm to about 2.0 mm,more preferably between 0.5 mm to about 1.5 mm, most preferably about1.0 mm. The thickness d3 of the backing portion 4123 may generally bebetween 1.5 mm to about 3.0 mm, more preferably between about 1.75 mm toabout 2.75 mm, and most preferably about 2.25 mm. Ultimately, theresultant Striking Thickness Ratio, as defined by Equation (2) above, isless than about 1.0, more preferably less than about 0.8, and mostpreferably less than about 0.7.

Focusing on the unique dovetail type undercut 4128 feature unique tothis embodiment of the present invention, FIG. 42 is provided with afurther enlarged view of the dovetail type undercut 4128 by focusing onthe circular region C shown in FIG. 41. Turning now to FIG. 42, we cansee that in addition to the thickness d2 of the face insert 4120 and thethickness d3 of the backing portion 4123, additional features of thedovetail type undercut 4128 is shown in more detail. First and foremost,we can see that the dovetail type undercut 4128 is angled at an angle θrelative to the loft of the striking face. The angle θ of between about40 degrees to about 65 degrees, more preferably between about 45 degreesto about 60 degrees, and most preferably between about 50 degrees toabout 55 degrees. This angle θ is critical to the proper functioning ofthe invention because if the angle θ is too low, then the metallicmaterial that wraps around the frontal portion of the striking facewould be too thin and would be prone to failure. However, the oppositeis also detrimental in that when the angle θ is too high, then the sharpangle created by the face insert 4120 makes it difficult to manufactureand could also be prone to failure.

Secondly, we can see that the depth d11 of the dovetail type undercut4128 is measured at the previously mentioned angle θ, and depicts thedepth of the dovetail type undercut 4128. Alternatively speaking, it canbe said that the face insert 4120 has complimentary dovetail shapedprotrusion 4129 nears its edges adapted to engage undercut 4128 to helpsecure the face insert 4120 to the backing portion 4123. The depth d11of the undercut 4128 or the distance of the complimentary dovetailshaped protrusion 4129, as shown in this embodiment of the presentinvention, may generally be between about 3 mm to about 6 mm, morepreferably between about 3.5 mm to about 5.5 mm, and most preferablybetween about 3.75 mm to about 5.25 mm. However, it should be noted thatlengths that are outside of this range could potentially work with thepresent invention, but the results provided would be less than optimal.

FIG. 43 of the accompanying drawings shows an enlarged cross-sectionalview of circular region B shown in FIG. 4 of a golf club head inaccordance with a further alternative embodiment of the presentinvention. In this embodiment of the present invention, the dovetailundercut 4328 may have slightly different shape, geometry to furtherimprove the performance of the golf club head. In addition, thetransition portion of the crown is also adjusted to further support theperformance enhancements of the golf club head.

In the embodiment of the present invention shown in FIG. 43, the angle θis reduced to be between 35 degrees to 60 degrees, more preferablybetween 40 degrees to about 55 degrees, and most preferably betweenabout 45 degrees to about 50 degrees. This angle θ is once againcritical to the proper functioning of the present invention because ifthe angle θ is too low, then the metallic material that wraps around thefrontal portion of the striking face would be too thin and would beprone to failure. However, the opposite is also detrimental in that whenthe angle θ is too high, then the sharp angle created by the face insert4120 makes it difficult to manufacture and could also be prone tofailure. Depth d11 shown here is similar to previous examples, and ismaintained in the range between about 3 mm to about 6 mm, morepreferably between about 3.5 mm to about 5.5 mm, and most preferablybetween about 3.75 mm to about 5.25 mm.

In an effort to further enhance the performance and durability of thegolf club head, the present invention also has a unique crown shapingand geometry. The crown portion of the golf club head begins with aconstant thickness portion 4331 having an increased thickness d14 ofbetween about 1.1 mm to about 1.4 mm, more preferably between about 1.15mm to about 1.35 mm, and most preferably between about 1.2 mm to about1.3 mm. The constant thickness portion 4331 may generally extendrearward from the rear of the transition between the face and the crownfor a distance d12 of between about 6 mm to about 11 mm, more preferablybetween about 6.5 mm to about 10.5 mm, and most preferably between about7.0 mm to about 10.0 mm. The frontal end of the constant thicknessportion 4331 begins where the internal radius of the crown ends andterminates where the thickness stops being at a constant thickness andtransitions into the transition portion 4333. The transition portion4333 may generally transition from a thickness of about 1.25 mm to abouta thickness of 0.4 mm over a span of a predetermined length d13. Thispredetermine length d13 may generally be between about 9.0 mm to about16 mm, more preferably between about 9.5 mm to about 15.5 mm, and mostpreferably between about 10 mm to about 15 mm.

It should also be noted here that the present embodiment of the presentinvention allows for the utilization of a bigger face insert 4320 with alarger frontal surface area than previous embodiments. In thisembodiment of the present invention, the face insert 4320 may have afrontal surface area of greater than prior embodiments. In the currentembodiment, the frontal striking face surface area may generally begreater than about 3,200 mm², more preferably greater than about 3,300mm², and most preferably greater than about 3,400 mm². This increase inthe central portion face insert 4320 frontal surface area will yield acentral portion to striking face ratio (as defined by Equation (1)above) that is greater than about 0.75, more preferably greater thanabout 0.80, and most preferably greater than about 0.85 all withoutdeparting from the scope and content of the present invention.

Other than in the operating example, or unless otherwise expresslyspecified, all of the numerical ranges, amounts, values and percentagessuch as those for amounts of materials, moment of inertias, center ofgravity locations, loft, draft angles, various performance ratios, andothers in the aforementioned portions of the specification may be readas if prefaced by the word “about” even though the term “about” may notexpressly appear in the value, amount, or range. Accordingly, unlessindicated to the contrary, the numerical parameters set forth in theabove specification and attached claims are approximations that may varydepending upon the desired properties sought to be obtained by thepresent invention. At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the scope of the claims,each numerical parameter should at least be construed in light of thenumber of reported significant digits and by applying ordinary roundingtechniques.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical value, however, inherently contains certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements. Furthermore, when numerical ranges ofvarying scope are set forth herein, it is contemplated that anycombination of these values inclusive of the recited values may be used.

It should be understood, of course, that the foregoing relates toexemplary embodiments of the present invention and that modificationsmay be made without departing from the spirit and scope of the inventionas set forth in the following claims.

What is claimed is:
 1. A golf club head comprising: a striking faceprovided near a forward portion of said golf club head; a body portionconnected to an aft portion of said striking face further comprising acrown, a sole, and a skirt, wherein said crown further comprises; aconstant thickness portion located near said striking face, and atransition portion located aft of said constant thickness portion,wherein said striking face further comprises; a perimeter portion madeout of a first material having a first density around a border of saidstriking face, and a central portion near a center of said striking facesurrounded by said perimeter portion, wherein said central portioncomprises a backing portion, wherein said central portion defined apocket having a dovetail shaped undercut, and said pocket is filled witha face insert having a dovetail shaped protrusion around its perimeter,said dovetail protrusion adapted to engage said dovetail shapedundercut, wherein said face insert is made out of a second materialhaving a second density, wherein said second density is less than saidfirst density, and wherein said dovetail shaped protrusion extends adistance (d11) between about 3 mm to about 6 mm into said dovetailshaped undercut.
 2. The golf club head of claim 1, wherein said constantthickness portion of said crown has a thickness of between about 1.1 mmto about 1.4 mm.
 3. The golf club head of claim 2, wherein said constantthickness portion of said crown has a thickness of between about 1.15 mmto about 1.35 mm.
 4. The golf club head of claim 3, wherein saidconstant thickness portion of said crown has a thickness of betweenabout 1.2 mm to about 1.3 mm.
 5. The golf club head of claim 2, whereinconstant thickness portion has a length of between about 6 mm to about11 mm.
 6. The golf club head of claim 5, wherein said constant thicknessportion has a length of between about 6.5 mm to about 10.5 mm.
 7. Thegolf club head of claim 6, wherein said constant thickness portion has alength of between about 7.0 mm to about 10.0 mm.
 8. The golf club headof claim 5, wherein said club head has a Striking Thickness Ratio ofless than about 1.0, said Striking Thickness Ratio defined as:${{Striking}\mspace{14mu}{Thickness}\mspace{14mu}{Ratio}} = {\frac{{depth}\mspace{14mu}( {d\; 2} )\mspace{14mu}{of}\mspace{14mu}{pocket}}{{thickness}\mspace{14mu}( {d\; 3} )\mspace{14mu}{of}\mspace{14mu}{backing}\mspace{14mu}{portion}}.}$9. The golf club head of claim 8, wherein said Striking Thickness Ratiois less than about 0.8
 10. The golf club head of claim 9, wherein saidStriking Thickness Ratio is less than about 0.7.
 11. A golf club headcomprising: a striking face provided near a forward portion of said golfclub head; a body portion connected to an aft portion of said strikingface further comprising a crown, a sole, and a skirt, wherein said crownfurther comprises; a constant thickness portion located near saidstriking face, and a transition portion located aft of said constantthickness portion, wherein said striking face further comprises; aperimeter portion made out of a first material having a first densityaround a border of said striking face, and a central portion near acenter of said striking face surrounded by said perimeter portion,wherein said central portion comprises a backing portion, wherein saidcentral portion defined a pocket having a dovetail shaped undercut, andsaid pocket is filled with a face insert having a dovetail shapedprotrusion around its perimeter, said dovetail protrusion adapted toengage said dovetail shaped undercut, wherein said face insert is madeout of a second material having a second density, wherein said seconddensity is less than said first density, wherein said dovetail shapedprotrusion extends a distance (d11) between about 3 mm to about 6 mminto said dovetail shaped undercut, wherein said dovetail shapedprotrusion forms an angle θ of between about 35 degrees of about 60degrees with said striking face, and wherein said distance (d11) isgenerally greater than the thickness (d3) of said backing portion. 12.The golf club head of claim 11, wherein said angle θ is between about 40degrees to about 55 degrees.
 13. The golf club head of claim 12, whereinsaid angle θ is between about 45 degrees to about 50 degrees.
 14. Thegolf club head of claim 13, wherein said golf club head has a CentralPortion to Striking Face Ratio of greater than about 0.75, said CentralPortion to Striking Face Ratio defined as:${{Central}\mspace{14mu}{Portion}\mspace{14mu}{to}\mspace{14mu}{Striking}\mspace{14mu}{Face}\mspace{14mu}{Ratio}} = \frac{{Frontal}\mspace{14mu}{Surface}\mspace{14mu}{Area}\mspace{14mu}{of}\mspace{14mu}{Central}\mspace{14mu}{Portion}}{{Frontal}\mspace{14mu}{Surface}\mspace{14mu}{Area}\mspace{14mu}{of}\mspace{14mu}{Striking}\mspace{14mu}{Face}}$15. The golf club head of claim 14, wherein said Central Portion toStriking Face Ratio is greater than about 0.80.
 16. The golf club headof claim 15, wherein said Central Portion to Striking Face Ratio isgreater than about 0.85.
 17. The golf club head of claim 16, whereinsaid constant thickness portion of said crown has a thickness of betweenabout 1.1 mm to about 1.4 mm.
 18. The golf club head of claim 17,wherein said constant thickness portion of said crown has a thickness ofbetween about 1.15 mm to about 1.35 mm.
 19. The golf club head of claim18, wherein said constant thickness portion of said crown has athickness of between about 1.2 mm to about 1.3 mm.
 20. The golf clubhead of claim 19, wherein constant thickness portion has a length ofbetween about 6 mm to about 11 mm.